Valve disk assembly having single orientation

ABSTRACT

A valve assembly 20 includes a housing 22, a stem 24, a reversible stop 30 and a retainer 32. A coupler 34, a rotatable ceramic disk 36, a fixed ceramic disk 38 and a bottom seal 40. Also form components of the valve assembly 30. The rotatable disk 36, the coupler 34 and a drive bar 90 of the stem 24 are assembled and are located within a bore 52 of the housing 22 with a shank portion 74 of the stem 24 extending outward from an opening 56 of the housing 22. A pair of ears 148 and 150 extend radially from a side 144 on diametrically opposite sides of the fixed disk 38. The ear 148 is located symmetrically about a centerline which passes through both ears 148 and 150. The ear 150 is wider than the ear 148, and includes a portion which is offset from the centerline. The bore 52 is formed with a pair of slots 70 and 72, which are complementary to the ears 148 and 150, respectively, for receipt of the fixed disk 38. Due to the offset portion of the ear 150 and the location of the ears 148 and 150 about the centerline, and the accommodating size and location of the slots 70 and 72 of the housing 22, the fixed disk 38 can be located within the bore 52 in only a single orientation and only a single position.

This application is a division of application Ser. No. 08/807,850, filedFeb. 26, 1997, now U.S. Pat. No. 5,832,952, which is a division ofapplication Ser. No. 08/546,640, filed Oct. 23, 1995, now U.S. Pat. No.5,681,028.

BACKGROUND OF THE INVENTION

This invention relates to a valve assembly and particularly relates to anon-rise valve assembly.

Faucets which are typically used in a lavatory or a kitchen may use avalve with a single-handle control or a two-handle control. In atwo-handle valving arrangement, the valves are located on each side of aspout of the faucet and are referred to as the left side valve, forcontrolling the supply of hot water, and the right side valve forcontrolling the supply of cold water. For many years, and to thepresent, one type of two-handle valve which has been in use includes astem which is threadedly mounted in a bonnet. When either of the handlesof the faucet is turned to open the respective valve, the stem isthreadedly operated and thereby rises from its closed position becauseof its threaded mounting to separate a compliant washer from its closedseat to thereby allow water to flow past the seat and eventually fromthe spout.

Another type of valve used in a two-handle faucet is a non-rise valveand employs two ceramic disks which are always in interfacing engagementand which are formed with openings to facilitate the flow of watertherethrough. When the openings of the disks are not aligned in anyrespect, the valve is closed to prevent the flow of water therethrough.When the valve handle and associated stem are turned, one of the diskswhich is attached to the stem is rotated relative to the other diskwhile the two disks remain in interfacing engagement. Eventually, theopenings of the disks are aligned and water is allowed to flow throughthe openings and out of the spout. In this type of valve, the stem ofthe valve does not rise as the valve is opened, in contrast to the valvewith the threadedly mounted stem noted above. A few examples of the manyvalves of the ceramic type are disclosed in U.S. Pat. Nos. 3,780,758;3,831,621 and 5,174,324.

Generally, in ceramic valves of this type, the stem is freely rotatablewithin the bonnet in a clockwise direction and a counterclockwisedirection. Therefore, a given design of a ceramic valve could be used onboth sides of a two-handle faucet, that is as a right side valve and asa left side valve to provide the turning direction typically associatedwith a cold water valve on the right side of the faucet and a hot watervalve on the left side of the faucet. However, a turning limit stop mustbe employed to limit the turning of the valve in each direction toone-quarter of a full turn. In order to take advantage of the premise ofusing ceramic valves of a common design on both sides of the faucet, areversible stop is used with each valve to limit the turning of the stemin one direction or the other depending on whether the valve is beingused on the right side or the left side of the faucet. An example of areversible stop which is used for this purpose is disclosed in U.S. Pat.No. 3,831,621.

When assembling the components of a ceramic valve of the type notedabove, it is critical that the components be assembled in the properrelationship and orientation, otherwise the valve will not function inthe manner intended. Typically, the components of the valves areassembled in a factory to form the valves. During the assembly process,the reversible stops are assembled so that each valve is either a hotwater or a cold water valve and the valves are segregated accordingly. Ahot water valve is then assembled into one of a pair of spaced endbodies on opposite ends of an underbody which is to the left of a centerbody thereof. A cold water valve is then assembled into the other endbody which is to the right of the center body. The underbody is thenassembled with other elements to form a faucet. The faucet is packagedand shipped, eventually, to an installation site where it is installedin a plumbing system. Thus, it is important that some provision be madeto insure that the reversible stop is assembled in the proper manner toprovide a hot water or a cold water valve so that, when that valve isassembled with the underbody, it is assembled in the appropriate endbody thereof.

During the period immediately following the assembly of the componentsof the valve, the valve is transported within the factory to variousstations for further processing. Also, individual valves may be packagedand sold as replacement units for installation with existing, previouslyinstalled faucets.

Current techniques and facilities for retaining the assembled reversiblestop with the valve assembly, typically include elements which requiretools to insert and remove the stop. This requires that the installercarry appropriate tools necessary for such actions. In the factory aswell as at the installation site, provision must be made for retainingthe reversible stop of the valve in assembly during periods of handling,shipment, storage, and ultimate assembly with other elements of a faucetat the factory or installation sites. In addition, provision must bemade for facilitating easy removal of the stop.

With respect to the valves which are installed as replacements inexisting faucets, provision must be made to insure that, when replacinga hot water valve or a cold water valve, the reversible stop isassembled in the appropriate manner for the valve to functionaccordingly. Of course, the same provision must be made to insure theappropriate assembly in the factory.

Currently, a bottom seal element is assembled at the bottom oftwo-handle valve assemblies of the type described above. The bottom sealmust be composed of a material which provides a water-tight seal at thebottom of the valve assembly while placing a limited stress on valvingcomponents which allow the valve assembly to be operated with relativeand comfortable ease. The bottom seals currently used include acompliant member which is composed of a relatively expensive material.Thus, it is important that provision be made for providing an effectivebottom seal which is relatively inexpensive.

At times, a homeowner may wish to convert a faucet from a knob-handleunit to a lever-handle unit. In this instance, only the knobs areremoved and replaced by levers. When only knobs are used, the reversiblestops are situated within the valve assembly in a precise manner toaccommodate the conventional turning for the hot and cold water valvesin the same direction, that is clockwise to close for both the hot andcold water valves. When levers are used, the hot and cold levers extendin generally opposite directions from each other when the valve is fullyclosed. When opening the lever-operated valves, the hot and cold valvesare conventionally turned in opposite directions. For example, the coldlever is turned in a clockwise direction and the hot lever is turned ina counterclockwise direction to open the valve. Thus, to open the hotwater valve for the knob assembly, the knob is turned in acounterclockwise direction, while to open the hot water valve for thelever assembly, the lever is turned in a counterclockwise direction.Therefore, provision must be made for easily reversing the hot watervalve assembly when converting from a knob assembly to a lever assembly,or vice versa, and for insuring that the reversible stop is properlyoriented to accommodate such change.

In view of the above-noted provisions, there is a need for a valveassembly which can be assembled in an efficient manner while insuringthat a reversible stop thereof is properly assembled for the valve tofunction in the intended manner. In addition, there is a need forfacilities which provide for the easy assembly and disassembly of thereversible stop. Further, there is a need for facilities which allow forthe easy and comfortable operation of the valve assembly while providingnecessary sealing in appropriate areas of the valve assembly.

SUMMARY OF THE INVENTION

In view of the foregoing needs, it is an object of this invention toprovide a valve assembly having facility for insuring that components ofthe valve are assembled in an intended manner for proper operationthereof.

Another object of this invention is to provide a valve assembly havingfacility for insuring that components of the valve assembly may beeasily assembled and disassembled.

Still another object of the invention is to provide for easy andcomfortable operation of the valve assembly while providing necessarysealing in appropriate areas.

With these and other objects in mind, this invention contemplates avalve assembly which includes a housing and a stem mounted within thehousing for free rotation relative thereto. A first end of the stemextends from a first opening of the housing. A first fluid-flow valveelement is located within the housing and is coupled to a second end ofthe stem for rotation therewith. The first valve element is formed witha surface which is in facing engagement with a first surface of a secondfluid-flow valve element fixedly attached within and to the housingadjacent a second end of the housing. A retainer is assembled at leastpartially within the second opening of the housing to assist inretention of the stem, the first valve element and the second valveelement within the housing. The retainer is formed with interfacingstructure which interfaces with a second surface of the second valveelement with only a portion of the interfacing structure in engagementwith the second surface of the second valve to apply a prescribed forceagainst the second surface of the second valve element to allow theturning of the stem and the first valve element relative to the secondvalve element while continuing to function as the second retainer.

This invention further contemplates a valve assembly which includes ahousing and a stem mounted within the housing for free rotation relativethereto. A first end of the stem extends from a first opening of thehousing and is formed with structure for supporting a reversible stopelement in a complementary manner. The reversible is formed withindicating structure on one surface thereof to provide indication of theorientation of the stop. A first fluid-flow valve element is locatedwithin the housing and is coupled to a second end of the stem forrotation therewith. The first valve element is formed with a surfacewhich is in facing engagement with a surface of a second fluid-flowvalve element fixedly attached within and to the housing adjacent asecond end of the housing. A retainer is assembled on the stem topreclude unintentional disassembly of the stop element from the stem.

Other objects, features and advantages of the present invention willbecome more fully apparent from the following detailed description ofthe preferred embodiment, the appended claims and the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings:

FIG. 1 is an exploded perspective view showing a valve assembly inaccordance with certain principles of the invention;

FIG. 2 is an assembled perspective view showing the valve assembly ofFIG. 1 in accordance with certain principles of the invention;

FIG. 3 is a sectional view showing structural features of the valveassembly of FIG. 1 in accordance with certain principles of theinvention;

FIG. 4 is a sectional view showing structural features of the valveassembly of FIG. 1 in accordance with certain principles of theinvention;

FIG. 5 is a sectional view showing a housing or bonnet of the valveassembly of FIG. 1 in accordance with certain principles of theinvention;

FIG. 6 is a sectional view showing structural features of the housing ofFIG. 5 in accordance with certain principles of the invention;

FIG. 7 is a partial perspective view showing an end of a stem of thevalve assembly of FIG. 1;

FIG. 8 is a perspective view showing structural features of one side ofa coupling of the valve assembly of FIG. 1;

FIG. 9 is a bottom view showing structural features of a first valveelement of the valve assembly of FIG. 1;

FIG. 10 is a top view showing structural features of a second valveelement of the valve assembly of FIG. 1;

FIG. 11 is a top view of the valve assembly of FIG. 2 showing a firstrelation between a reversible stop on the stem of FIG. 7 and stopsurfaces on the housing of FIG. 5 in accordance with certain principlesof the invention;

FIG. 12 is a partial perspective view of the valve assembly of FIG. 1showing a second relation between the reversible stop and the stopsurfaces of FIG. 11 in accordance with certain principles of theinvention;

FIG. 13 is a top view of the valve assembly of FIG. 1 showing the secondrelation between the reversible stop and the stop surfaces of FIG. 12 inaccordance with certain principles of the invention; and

FIG. 14 is an enlarged partial sectional view of a bottom seal inaccordance with certain principles of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1, a valve assembly 20 includes a housing or bonnet 22and a stem 24, both of which are composed of a copper alloy such as, forexample, brass. The valve assembly 20 further includes a thrust washer26, an O-ring 28, a reversible stop 30, which is composed of stainlesssteel, and a retainer 32, composed of a resilient material such as, forexample, rubber. A coupling 34, a rotatable ceramic disk 36, a fixedceramic disk 38 and a bottom seal 40, composed of an EPDM rubber,complete the components of the valve assembly 30. It is noted that othermaterials could be used without departing from the spirit and scope ofthe invention.

As shown in FIGS. 3, 4 and 5, the housing 22 is formed with a lowercylindrical section 42, a threaded section 44, an intermediate flaredsection 46, a hexagonal section 48 and an upper cylindrical section 50.The housing 22 is formed with a bore 52 which extends axiallytherethrough from a lower opening 54 to an upper opening 56. A firstshoulder 58 is formed in the bore 52 near the opening 54 and a secondshoulder 60 is formed in an intermediate portion of the bore. An endsurface 62 is formed on the housing 22 and surrounds the upper opening56 of the bore 52.

A pair of opposed stop tabs 64 having stop surfaces 66 (FIG. 1) areformed with and extend in an axial direction from the end surface 52. Asshown in FIGS. 1, 2, 3 and 5, a pair of fluid-flow windows 68 are formedthrough opposed portions of the lower cylindrical section 42 immediatelybelow the threaded section 44. Referring to FIGS. 5 and 6, a first slot70 is formed within the bore 52 and extends in an axial directionbetween the shoulder 58 and the adjacent window 68. A second slot 72 isformed within the bore 52 at a location opposite the slot 70 and alsoextends between in an axial direction between the shoulder 58 and theadjacent window 68. The slot 70 is formed with a prescribed width whichis centered about a horizontal centerline as viewed in FIG. 6. The slot72 is wider than the slot 70 but is offset somewhat from the horizontalcenterline as viewed in FIG. 6. As shown, the portions of both of theslots 70 and 72 above the horizontal centerline extend an equaldistance. However, the portion of the slot 72 below the centerlineextends considerably more from the centerline than the comparableportion of the slot 70.

As shown in FIG. 1, the stem 24 is formed with a shank portion 74 and adisk-like base 76 integrally joined to the lower end of the shankportion. The base 76 is formed with an upper surface 77 which iscontiguous with the shank portion 74. An annular groove 78 is formedabout an intermediate section of the shank portion 74 for eventualreceipt of the O-ring 28. The upper end of the shank portion is formedwith a first set of splines 80 and a second set of splines 82 spacedfrom the first set by an annular groove 84. The splines 80 and 82 extendin an axial direction and are aligned with each other. A space 86 isformed in the first set of splines 80 in an area which would normally beoccupied by one of the splines. A space 88 is formed in the second setof splines 82 in an area normally occupied by one of the splines. Thespaces 86 and 88 are aligned as shown in FIG. 1. As shown in FIG. 7, adrive bar 90 is formed diametrically and nearly fully across theunderside of the base 76 of the stem 24. The drive bar 90 is elongatedand slender and is formed with four essentially squared corners.Referring to FIGS. 1 and 2, the reversible stop 30 is formed in adisc-like, flat configuration having a pair of ears 92 extendingradially outward from opposite sides of a circular body 94. The stop 30is formed with a large axial opening 96 through the body 94 with aseries of juxtaposed spaces 98 arranged radially on the inside of theopening. Each of the spaces 98 are shaped in a configuration essentiallythe same as the configuration of each of the splines 80 and 82 of thestem 24. A plurality of radially inward projections 99 are formedbetween adjacent spaces 98 and are the most radially inboard portions ofthe stop 30. In addition, a wide spline 100 is formed on the inside ofthe opening 96 of the stop 30 in radial arrangement with the spaces 98and is shaped in essentially the same configuration as the space 86 ofthe stem 24. The ears 92 are each formed with a pair of stop surfaces102. As shown in FIGS. 1, 2 and 11, a first flat major surface 104 ofthe stop 30 is formed without any interruptions while a second flatmajor surface 106, on a side of the stop opposite the first majorsurface, is formed with two "V" shaped grooves 108 which are aligned andon opposite sides of the opening 96. The retainer 32 is formed in acircular configuration and is composed of a compliant material such as,for example, silicone. The retainer 32 is formed with a rectangularcross section as shown in FIGS. 3 and 4.

As shown in FIG. 1, the coupler 34 is formed generally in a circularconfiguration. The coupler 34 is composed of a plastic material such as,for example, a thermoplastic material available from DuPont under thetrademark "Delrin." On a first major surface 110 of the coupler 34, fourpie-shaped cutouts 112 are formed in a four-quadrant arrangement and anelongated, slender slot 114 is formed diametrically nearly fully acrossthe surface. The slot is configured somewhat as a complementaryconfiguration to the configuration of the drive bar 90. As shown in FIG.1, four corners 115 of the elongated slot 114 are formed with thethermoplastic material of the coupler 34 to the extent that the cornersare rounded from the top of the slot to the base thereof. In thisrespect, the four corners 115 of the slot 114 differ from the squaredcorners of the drive bar 90.

Referring to FIG. 8, the coupler 34 is formed with a second majorsurface 116 having a pair of diametrically spaced, cube-like blocks 118extending outward from opposite edges of the side. A pair ofdiametrically-spaced guide members 120 are also formed on the secondmajor surface 116 and extend outward from opposite edges of the surface.The guide members 120 are each formed with a flat surface 122 whichinterfaces with the flat surface of the other guide member and which areparallel with each other and with the alignment of the blocks 118. Asshown in FIG. 8, a plurality of crush ribs 123 are formed on the flatsurfaces 122 of the guide members 120 and on the interfacing surfaces ofthe blocks 118 as an integral portion of the coupler 34.

As shown in FIG. 1, the rotatable disk 36 is formed with a flat uppersurface 124 with convex end surfaces 126 and spaced, parallel, straightside edges 128. A pair of notches 130 are formed centrally in each ofthe convex end surfaces 126 and the flat upper surface 124. Referring toFIG. 9, the rotatable disk 36 is formed with a flat bottom surface 132having convex end edges 136 which are contiguous with the convex endsurfaces 126. A pair of "V" shaped spaces 138 are formed on oppositesides of the rotatable disk 36 and are contiguous with the straight sideedges 128. The spaces 138 form a pair rectangular openings on oppositesides of the disk 36 and a pair of "V" shaped opening at the bottom ofthe disk. A series of step surfaces 140 are formed in a ceiling of eachof the spaces 138 as shown in FIGS. 3, 4 and 9.

Referring again to FIG. 1, the fixed disk 38 is formed with a flat uppersurface 142 and a circular side 144. As shown in FIG. 10, the disk 38 isformed with a flat bottom surface 146. As shown in FIGS. 1 and 10, afirst ear 148 and a second ear 150 extend radially outward from oppositeportions of the side 144 of the disk 38. The first ear 148 is locatedsymmetrically about a centerline as viewed in FIG. 10 while the secondear 150 has a portion which offset to the right of the centerline. Apair of pie-shaped openings 152 are formed through the disk 36.

As shown in FIGS. 1, 3, 4 and 14, the bottom seal 40 is formed in acircular configuration with a circular groove 154 formed centrally ineach side of the seal. Each of the grooves 154 of the seal 40 is formedwith spaced sidewalls 156 and a base 158 which extends between thesidewalls and which faces outward of the seal. The formation of eachgroove 154 in the seal 40 results in an outward facing surface 160 on anoutboard side of the groove and an outward surface 162 on an inboardside of the groove. Thus, the surfaces 160 and 162 are separated by thegroove 154 and the surfaces 158, 160 and 162 all face in an outwarddirection with respect to the seal 40. The seal 40 is formed with anaxial opening 164.

In the assembly of the components of the valve assembly 20 as viewed inFIGS. 3 and 4, the thrust washer 26 is positioned over the shank portion74 of the stem 24 and is located on the upper surface of the base 76.The O-ring 28 is placed over the shank portion 74 of the stem 24 and iscompliantly located in the annular groove 78 formed in the shankportion. The rotatable disk 36 is then assembled with the coupler 34 byaligning the blocks 118 of the coupler with the notches 130 of the disk.Thereafter, the coupler 34 and the disk 36 are moved relatively towardeach other so that the blocks 118 move into the notches 130 and thestraight side edges 128 of the disk are guided between the guide members120 of the coupler. Eventually, the surface 116 of the coupler 34 isplaced in interfacing engagement with the surface 124 of the disk 36. Asthe straight side edges 128 of the rotatable ceramic disk 36 is movedpast the flat surfaces 122 of the coupler 34, the edges of the diskengage and deform, and essentially crush, the crush ribs 123 to theextent that the disk and the coupler fit snugly together. Thisfacilitates and provides a tight fit between the coupler 34 and therotatable disk 36 and precludes the tendency for lost motion between thecoupler and the disk between the driving rotation of the coupler and thedriven rotation of the disk.

The stem 24 is then manipulated to align, and assemble, the drive bar 90thereof with the elongated slot 114 of the coupler 34. As the drive bar90 is inserted into the slot 114, the metal material at the four squaredcorners of the bar engages and deforms, and essentially crushes, thethermoplastic material of the curved corners 115 to the extent that thebar fits snugly into the slot. This facilitates and provides arelatively tight fit between the bar 90 and the slot 114 and precludesthe tendency for lost motion between the driving rotation of the stem 24and the driven rotation of the coupler 34.

With the relatively tight fit between the bar 90 of the stem 24 and theslot 114 of the coupler 34, and between the coupler and the rotatabledisk 36, as described above, there is essentially no opportunity for anylost motion in the use of the valve assembly 20. This provides acomfortable and assuring responsive feeling to the user of the valveassembly 30.

A lubricating grease is applied to the shank portion 74 of the stem 24between, and on either side of, the thrust washer 26 and the O-ring 28.Also, grease is applied in the area of the junctures of the bottom ofthe stem 24 and the top of the coupler 34, the bottom of the coupler andthe top of the rotatable disk 36, and the disk 36 and the fixed disk 38.

The shank portion 74 of the stem 24 is then inserted into the bore 52 ofthe housing 22 through lower opening 54 thereof and is moved into thebore so that the upper end of the shank portion extends outward from theupper opening 56 of the bore as shown in FIGS. 3 and 4. However, thestem 24 is not moved fully to its final position within the housing 22at this time. Thereafter, the fixed disk 38 is positioned with the uppersurface 142 thereof facing the bottom surface 132 of disk 36 and withears 148 and 150 thereof aligned with slots 70 and 72, respectively, ofhousing 22. It is noted that, due to the offset configuration of the ear150, and the corresponding offset configuration of the slot 72, thefixed disk 38 can be inserted into assembly with housing 22 only in oneorientation. This feature insures that the fixed disk 38 is alwaysassembled with the rotatable disk 36 in the proper relationship foroperation of the valve assembly 20.

The fixed disk 38 is then moved into a position where the bottom surface132 of disk 36 is in interfacing engagement with the top surface 142 ofthe fixed disk. During the period when the fixed disk 38 is beingassembled as noted above, the assembly of the stem 24, the coupler 34and the rotatable disk 36 remain partially positioned within the housing22 to provide a back wall against which the fixed disk can be properlyaligned within the housing as the ears 148 and 150 are being insertedinto the slots 70 and 72, respectively.

Thereafter, the fixed disk 38 is pushed further into the housing 22whereby the stem 24, the coupler 34 and the rotatable disk 36 are fullyseated in their final position within the housing. In this assembly, thethrust washer 26 is sandwiched between the upper surface 77 of the stem24 and the shoulder 60 of the housing 22. Also, the splines 80 and 82 ofthe stem 24 extend fully outward from opening 56 of the housing 22 intheir final position.

The bottom seal 40 is then assembled within the opening 54 of thehousing 22 and is pressed into engagement with the bottom surface 146 ofthe fixed disk 38. Lower portions of the seal 40 extend outward from theopening 54 for subsequent sealing engagement with a seat in an end body(not shown) associated with the faucet. The outer diameter of the seal40 is slightly larger than the diameter of opening 54 of the housing 22whereby the seal is frictionally held within the opening. This providesan assist in retaining the assembled stem 24, coupler 34, rotatable disk36 and the fixed disk 38 within the housing. In the past, a seal usedfor this purpose was composed of a silicone rubber, a soft materialwhich deflects easily but is relatively expensive. In an effort todesign a replacement seal for the seal composed of silicone rubber, itwas determined that a seal, such as the seal 40, could be composed of anEPDM rubber which is less costly and is sufficiently resistant to thechemicals of the water passing therethrough. However, EPDM rubber isharder and stiffer than silicone rubber and requires greater force fordeflecting a given volume. If the full interfacing surface of a sealcomposed of EPDM rubber was placed in engagement with the fixed disk 38,the turning of the stem 24 by the user of the associated faucet would bedifficult due to the area of frictional contact between the seal and thefixed disk, the spring constant of the material and the composition ofthe material.

By forming the annular groove 154 in the seal 40, only the areas ofsurfaces 160 and 162 engage the bottom surface 146 of the fixed disk 38which provides a watertight seal and sufficient frictional contact toallow for easy turning of the stem 24 and disk 36 during use of theassociated faucet. With this arrangement, there is less comparablematerial to deflect and thereby less force is required. Also, it isnoted that the spaced surfaces 160 and 162 and the surface of the base158 interface with the bottom surface 146 of the fixed disk 38. However,only the spaced surfaces 160 and 162 of the seal 40 apply a prescribedforce against the bottom surface 146 of the disk 38 to allow the turningof the stem 24 and disk 36 while the seal continues to assist inretaining the assembled components within the housing 22.

The compliant retainer 32 is then stretched as it is moved over thefirst set of splines 80 and is compliantly placed into the annulargroove 84. In this position, the radially outer portions of the retainer32 occupy an area directly above an area which eventually will beoccupied by the radially inward projections 99 of the stop 30.

The reversible stop 30 is then positioned over the upper end of theshank portion 74 of the stem 24 and is oriented so that the wide spline100 thereof is located in alignment with the wide space 86 of the shankportion. In this position, the spaces 98 of the stop 30 are aligned withthe first set of splines 80 formed at the upper end of the shank portion74. The stop 30 is then moved over the first set of splines 80, past theretainer 32 previously assembled in the annular groove 84 and onto thesecond set of splines 82 whereby the wide spline 100 of the stop islocated within the wide space 88 formed on the shank portion adjacentthe second set of splines.

As the stop 30 is moved past the retainer 32, the radially outwardportions of the retainer are compressed momentarily by the radiallyinward projections 99 of the stop to allow the stop to be assembled ontothe splines 82. Once the stop 30 has been moved past the retainer 32,the radially outward portions of the retainer decompress and extend overthe radially inward projections 99 of the stop which thereby preventsthe stop from unintentionally moving outward of the stem 24 from itsmounted position on the splines 82. If it is necessary to remove thestop 30, the reverse procedure is effected. By use of the retainer 32 asdescribed above, the stop 30 can be easily and quickly removed withoutany special tooling and without dismantling. any other components of thevalve assembly 20.

In the past, and currently, manufacturers of two-handle faucets adopt aturning convention for the direction in which the respective valves areto be turned to open and close the hot water and cold water valves. Forexample, in one convention, when round knob-like handles or crosshandles are used, both the hot water valve and the cold water valve areturned counterclockwise to open the valves and clockwise to close thevalves. If a faucet employing the round or cross handles is to beconverted to a lever handle faucet, the hot water valve will continue touse the convention noted above with respect to the round or crosshandles. However, the cold water valve must now be turned clockwise toopen the valve and counterclockwise to close the valve. Therefore, thereversible stop 30 must be removed and manipulated to accommodate thelever handle convention in accordance with certain principles of theinvention. Other conventions could be used with the round or crosshandles, and with the lever handles, which could utilize the reversiblestop 30 as described and claimed herein without departing from thespirit and scope of the invention.

If the valve assembly 20 is to be assembled with a two-handle faucetusing round or cross handles for controlling both the hot water side andthe cold water side, the stop 30 is assembled as shown in FIGS. 2 and 11with the plain-side surface 104 facing up and the ears 92 being locatedto the clockwise right of the tabs 64. In this arrangement, theillustrations of FIGS. 2 and 11 depict an open valve whereby the spaces138 of the rotatable disk 36 are aligned with the pie-shaped openings152 of the fixed disk 38. Water will flow through the opening 164 of theseal 40, through the openings 152 of the fixed disk 38, through thespaces 138 of the rotatable disk 36 and through the windows 68 formed inthe housing 22. When the stem 24 is turned clockwise to the extentpermitted by the tabs 64 and ears 92, the valve will be closed wherebythe spaces 138 of the rotatable disk 36 are moved so that no portions ofthe spaces overlap with any portions of the pie-shaped openings 152 ofthe fixed disk 38. It is noted that the extreme limit positions forturning the valve from fully closed to fully open allows the stem 24 androtatable disk 36 to be turned approximately one quarter of a fullrevolution.

When the faucet described above is to be converted from a round handleor a cross handle to a lever handle, an installer removes the round orcross handle from atop the stem 24 of the hot water valve assembly 20and replaces the handle with a lever handle. With respect to the coldwater valve assembly 20, the round or cross handle is removed by theinstaller from atop the stem 24 to expose the reversible stop 30. Thestop 30 is then gripped by the installer and easily removed as describedabove without the use of any tools and without removing any othercomponent of the valve assembly 20. The installer then flips the stop 30over so that the surface 106 is facing upward and the wide spline 100 ofthe stop is in alignment with wide spaces 86 and 88 of the stem 24. Thestop 30 is then reinserted onto the splines 80, biasingly past theretainer 32 and onto the splines 82 whereby the ears 92 are located tothe counterclockwise left of the tabs 64 as viewed in FIGS. 12 and 13.The position of the stop 30 in FIGS. 12 and 13 represent a fully openvalve. By turning the stem 24 in a counterclockwise direction as viewedin FIGS. 12 and 13, the valve will be closed.

When the stop 30 is flipped over as described above, the grooves 108will appear and, when the stop is reinserted, will provide indicationthat the components of the valve assembly 20 have been assembled in anorientation to be used as a cold water valve with a lever handle underthe convention described above. Of course, the stop 30 could beassembled initially at the factory for use with a lever handle where theupwardly facing grooves 108 provide indication to the factory people ofthe intended use as well as providing indication to the ultimate on-siteinstaller of the faucet. This feature is also an advantage to thedo-it-yourselfer who installs and completes such conversion projectswithout the need for professional assistance. Further, plumbers andinstallers who are working on tract projects involving multiple houseshave a limited time in which to accomplish plumbing installations. Theindicating feature of the stop 30 and the ease of removal and reversalthereof without the need for any tooling or dismantling other componentsof the valve assembly 20 provide the opportunity for the replacementand/or installation process to be accomplished in relatively shortperiods of time.

As noted above, the premise of providing an indicating structure, suchas, for example, the grooves 108, on one side of the stop 30 could beused with other valve-turning-direction conventions for turning thevalves of a two handle faucet without departing from the spirit andscope of the invention.

In general, the above-identified embodiment is not to be construed aslimiting the breadth of the present invention. Modifications, and otheralternative constructions, will be apparent which are within the spiritand scope of the invention as defined in the appended claims.

What is claimed is:
 1. A valve assembly, which comprises:a housinghaving a bore therethrough; a stem mounted within the bore of thehousing for free rotation relative thereto and having an end within thebore: a first fluid-flow valve element located within the bore of thehousing and coupled to the end of the stem for rotation therewith; thefirst valve element formed with a first-element surface which faces awayfrom the stem when the stem is coupled to the first valve element; asecond fluid-flow valve element fixedly attached within the bore of thehousing adjacent a second end of the housing; the second valve elementformed with a second-element surface which faces away from the secondend of the housing; the second valve element formed with a firststructure and the housing formed with a second structure within the borethereof which is complementary in configuration to the configuration ofthe first structure to limit the assembly of the second valve elementwithin the housing to a single orientation and position where thefirst-element surface will interface only with the second-elementsurface.
 2. A valve assembly, which comprises:a housing having a boretherethrough; a stem mounted within the bore of the housing for freerotation relative thereto and having an end within the bore: a firstfluid-flow valve element located within the bore of the housing andcoupled to the end of the stem for rotation therewith; a secondfluid-flow valve element fixedly attached within the bore of the housingadjacent a second end of the housing; the second valve element formedwith a first structure and the housing formed with a second structurewithin the bore thereof which is complementary in configuration to theconfiguration of the first structure to limit the assembly of the secondvalve element within the housing to a single orientation andposition;wherein the first structure comprises: a first ear formedradially outward from a first side of the second valve element; a secondear formed radially outward from a second side of the second valveelement opposite the first side; the first ear being formed with a firstprescribed width having equal lateral portions on each side of a linepassing through the first ear and the second ear; and the second earbeing formed with a second prescribed width which a greater dimensionthan the first prescribed width with a greater lateral portion of thewidth being on one side of the line than on the other side of the line.3. A valve assembly, which comprises:a housing having a boretherethrough; a stem mounted within the bore of the housing for freerotation relative thereto and having an end within the bore: a firstfluid-flow valve element located within the bore of the housing andcoupled to the end of the stem for rotation therewith; a secondfluid-flow valve element fixedly attached within the bore of the housingadjacent a second end of the housing; the second valve element formedwith a first structure and the housing formed with a second structurewithin the bore thereof which is complementary in configuration to theconfiguration of the first structure to limit the assembly of the secondvalve element within the housing to a single orientation andposition;wherein the second structure comprises: a first slot formed ina first side of the bore of the housing and facing radially inward; asecond slot formed in a second side of the bore of the housing oppositethe first side and facing radially inward; the first slot being formedwith a first prescribed width having equal lateral portions on each sideof a line passing through the first slot and the second slot; and thesecond slot being formed with a second prescribed width of greaterdimension than the first prescribed width with a greater lateral portionof the width being on one side of the line than on the other side of theline.
 4. The valve assembly as set forth in claim 3, wherein the firststructure comprises:a first ear formed radially outward from a firstside of the second valve element; a second ear formed radially outwardfrom a second side of the second valve element opposite the first side;the first ear being formed with a first prescribed width having equallateral portions on each side of a line passing through the first earand the second ear; and the second ear being formed with a secondprescribed width of greater dimension than the first prescribed widthwith a greater lateral portion of the width being on one side of theline than on the other side of the line; and the valve assembly furthercomprises:the first ear of the second valve element being located in thefirst slot of the housing; and the second ear of the second valveelement being located in the second slot of the housing.